Miller COOLMATE 12 User manual

August 1978 FORM: OM-621A
Effective With Style No. HG-1
MODEL
Coolmate 12
WNERS
ANUAL
MILLER ELECTRIC MFG. CO.
718 5. BOUNDS ST. P.O. Box 1079
APPLETON, WI 54912 USA
NWSA CODE NO. 4579
PRINTED IN U.S A,
EI TS
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EFFECTIVE: FEBRUARY 20, 1978
This warranty supersedes all previous MILLER warranties and is ex-
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY —Miller Electric Mfg. Co., Apple-
ton, Wisconsin warrants to Customer that all mew and unused
Equipment furnished by Miller is free from defect in
workmanship and material as of the time and place of
delivery by Miller. No warranty is made by Miller with
respect to engines, trade accessories or other items manu-
factured by others. Such engines, trade accessories and other
items are sold subject to the warranties of their respective
manufacturers, if any. The manufacturers warranty on
engines is for a period of one year.
MILLER warranty does not apply to components having
normal useful life of less than one {1} year, such as spot
welder tips, relay and contactor points, MILLERMATIC
parts that come in contact with the welding wire including
nozzles and nozzle insulators where failure does not result
from defect in workmanship or material.
in the case of Miller's breach of warranty or any other
duty with respect to the quality of any goods, the exclusive
remedies therefor shail be, at Miller's option, (1) repair or (2)
replacement or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at Customer's risk and expense. All transactions are F.0.B.
Appleton, Wisconsin. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the
warranty claim procedures to be followed.
As a matter of general policy only, Miller may honor an
original user's warranty claims on warranted Equipment in
the event of failure resulting from a defect within the
following periods from the date of delivery of Equipment to
the original user:
1. Arc welders, power sources, and components. . 1 year
2. Original main power rectifiers . ............ 3 years
{Labor — 1 year only)
3. All welding guns and feeder/guns .......... 90 days
À. Al! other Millermatic Feeders ............. 1 year
provided that the user so notifies Miller in writing within thirty
(30) days of the date of such failure.
5, Replacementor repair parts exclusive of labor 60 days
ANY EXPRESS WARRANTY NOT PROVIDED
HEREIN AND ANY IMPLIED WARRANTY, GUARANTY
OR REPRESENTATION AS TO PERFORMANCE, AND
ANY REMEDY FOR BREACH OF CONTRACT WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY
IMPLICATION, OPÉRATION OF LAW, CUSTOM OF
TRADE OH COURSE OF DEALING, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT
TO ANY AND ALL EQUIPMENT FURNISHED BY
MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE
OF WELDING EQUIPMENT AND NOT, FOR CONSUMERS
OR CONSUMER USE. MILLER WARRANTIES DO NOT
EXTEND TO, AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLER'S WARRANTIES TO, ANY
CONSUMER,
io LL eo | У аой
и E k Se RARE
— SECTION 1 - INTRODUCTION
Overall Dimensions Motor Motor | Ampere Tank
(Inches) Weight | Input Frequency| Speed Input Capacity
Width | Height | Length | (Pounds) | Voltage | Phase (Hertz) (RPM) | (Full Load) | (US Gallons)
31-1/4 1 11-116 23 112 115VACI Single 60 1725 5.0 12
Figure 1-1. Specifications
1-1. GENERAL 1-4. SAFETY
This manual has been prepared especially for use in familiar-
izing personnel with the design, installation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
1-2. RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Style) Numbers of the equipment be supplied.
1-3. DESCRIPTION
This coolant system consists of an electric motor, steel tank,
and a high pressure pump to circulate the coolant. A bypass
valve is installed in the pump discharge line as a pressure
relief.
The delivery rate is as follows: (Water Coolant — 60°F}
0 pounds pressure 1.49 gallons per minute
20 pounds pressure 1.35 gallons per minute
40 pounds pressure 1.21 gallons per minute
60 pounds pressure 1.07 gallons per minute
80 pounds pressure 0.94 gallons per minute
100 pounds pressure 0.80 gallons per minute
8 SECTION 2 - INSTALLATION
2-1. LOCATION (Figure 2-1)
Holes are provided in the coolant system top and bottom for
mounting purposes. The top holes are provided to mount the
welding power source onto the coolant system. The bottom
holes are provided to mount the coolant system onto a sta-
tionary object or optional running gear, if desired. Figure 2-1
gives overall dimensions and mounting hole layout.
po
31-174"
25-1/2"
| >
<
EU
3/8"-16
: Ja Threaded
e | Te Hales
< 9/16" Dia. 6”
a _ 4 Holes > >
25-172" та o
a . 7 i - .
1-1/4" TC-003 557
Figure 2-1. Overall Dimensions and Mounting Hole Layout
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a safety hazard to
| personnel. 1
IMPORTANT
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
i ment. I
NOTE
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
2-2. ELECTRICAL INPUT CONNECTIONS (Figure 2-2)
Return Line
Receptacle
Coolant Tank
Access Doar
Pump Outlet
Receptacle
Viewing
Port
Motor/Pump
Access Panel
Pump
Bypass
Valve &
Cap Nut a Power Cord
и Motor Motor
Lubrication And Plug
Pump Cups
TC-003 558
Figure 2-2. Component Location
OM-621 Page 1
2-3.
A three foot cord with attached three prong plug is provided
to conduct power from a 115 volts ac, 60 hertz power supply
to the coolant system. It is recommended that the welding
power source 115 VAC receptacle be utilized to provide 1156
VAC power for the coolant system. By doing thusly, the
coolant system will be operative whenever the welding power
source is energized.
COOLANT CONNECTIONS (Figure 2-2)
A PUMP OUTLET receptacie and a RETURN LINE recep-
tacle are provided to connect the welding gun coolant hoses.
Both of these receptacles have left-handed threading.
3-1.
4-1.
Page 2
BYPASS VALVE (Figure 2-2)
A bypass valve is installed in the pump discharge line for
providing pressure relief, if the discharge line should be
closed for any reason. Factory setting of the bypass valve is
at 45 lbs. pressure. Pressures up to 100 Ibs. may be used for
elevating coolant to approximately 100 feet. Pressures in
excess of 100 PSI should be avoided as this will overload the
motor.
To adjust the bypass valve pressure, remove the motor/pump
access panel. Remove the cap nut and turn the pressure
COOLANT SYSTEM TANK
Coolant system tanks should be cleaned and fresh coolant
and lubricant added periodically. For every twelve gallons of
coolant, a single teaspoonful of common laundry bleach
should be added to the coolant system after fresh coolant
and lubricant are added. The bleach prevents bacteria growth.
Useful life of the coolant mixture will be measurably
extended.
The use of demineralized coolant is also advised in the
i coolant system, if available. |
2-4.
COOLANT AND LUBRICANT INSTALLATION
(Figure 2-2)
Coolant system pumps require some lubricant in the coolant
to lubricate the packings of the pump. The suggested ratio is
about one quart to every twelve gallons of coolant. This unit
is shipped with the proper amount of lubricant which is to be
added to the solution when the coolant system is first placed
into operation,
The coolant tank may be filled by loosening the access doar
screw and lifting the access door. The tank should then be
filled with coolant until the coolant level is to the center of
the viewing port. Replace the access door.
3-2.
4-2.
4-3.
adjustment screw clockwise to increase pressure. Replace cap
nut to lock the pressure adjustment screw at the desired
pressure. Replace the motor/pump access panel.
VIEWING PORT (Figure 2-2)
The viewing port purposes are twofold: When the coolant
level is in the center of the viewing port the coolant tank is
filled to the proper capacity. In addition, the splashing of the
coolant against the viewing port indicates that the coolant
system is functioning properly.
COLD WEATHER MAINTENANCE
Where freezing conditions may be encountered, permanent
antifreeze may be substituted for the lubricant mentioned
above except that the mixture will be determined by the
temperature conditions anticipated. Permanent antifreeze has
sufficient lubricity for adequate pump fubrication. The pump
has graphite bearings which require no more lubrication than
that contained in the coolant.
MOTOR LUBRICATION (Figure 2-2)
The motor is provided with lubrication cups which should be
filled with SAE 20 oil periodically.
August 1978 FORM: OM-621A
Effective With Style No. HG-1
MODEL
Coolmate 12
Y -596 £00-Ad 1
AjquessYy ajapduto”7 — y 940514
OM-621 Page 1
Item Factory
No. Part No. Description Quantity
Figure A Complete Assembly
1 010494 BUSHING, snap 1-3/8 ID x 1-3/4 hole eK RE 1
2 601890 RIVET, blind 1/8 dia 1/8 grip .... oii ee ee eee as 1
3 000679 COVER, tank oe ee ee ee еек. 1
4 604 804 SCREW, sheet metal - hex washer hd No. 8x 3/8 ......... ci... 6
5 004 727 TANK ee eee ee 1
6 603105 HOSE, braided5/161D x 1{orderbyfoot).......... 0. evra... 4 ft,
7 010323 CLAMP, hose 1/4 to 5/8 clamp dia ........._.eeese00emenaárcorere:eda era 5
8 039599 FITTING, brass- barbed male 5/16 TBG x 1/4 МРТ ....................... 4
9 035632 STRAINER ... oe RER ee 1
10 604538 WASHER, flat-steel SAE 5/16 .. 1.221011 4 1144 4 4 24 4 4 4 ea ee 4 a ea a a La 000 4
11 6004725 BOLT, carriage - steel 5/16-18 x 3/4 ....... 000000000 a a a a квин) 1
12 000654 CORD SET, power 3ft .................. ee eee 1
13 010610 CONNECTOR, clamp - cable 1/2... ee ieee ns 1
14 027803 MOTOR Lo ot ee ee te ee ee ee 06 1
15 010357 RECEPTACLE, clipon NO. 2 80raw oi iit te tee eee een 5
16 602 207 WASHER, lock - steel split 1/4 ................ ee ieee a 1
17 601865 NUT, steel -hex full 1/4-20 e erescederarvavenrer—erar 1
18 010594 GROMMET, rubber 1/21D x Tinch hole 1/16groove . ..................... 1
19 601954 SCREW, cap - steel hex hd 1/4-20 x 3/4 . . ini 4 4 a da a en a a a eee 6 1
20 010678 FITTING, brass - pipe street 1/4 NPT tii te teres eens 4
21 010428 COUPLER, motor to pump.....e.e..reoe..eesredarenerraw0traneoaon over: 1
22 602180 SCREW, set - steel socket hd 5/16-18 x 1/4... ..... —.e.r0r.edemeean. 4
23 000 848 PUMP, coolant............... 2... eadrerrecinenadvavarenanarerdera 1
24 604537 NUT, steel - hex full 5/16-18 Lo ite eee 4 aa es ea ea a ane 0 4
25 602211 WASHER, lock - steel split 5/16 ............... a 4
26 000868 BRACKET, mounting - PUMP ....e..osoecoeeececcereredrrrarecxorrerdererco 1
27 015715 GROMMET, rubber 11/16 ID x 1 inch hole 5/64 groove . . .................. 1
28 010853 FASTENER, screw - siotted hd No. 2 ......... ii iii i een 5
29 000664 DOOR, access ............... ...raesicoreroneamaronóraroróarecenea, 1
30 010855 RETAINER, screw No. 2 1.111400 4 44 LR LA 4 4 4 4 1 4 0 0 4 0 4 4 4 4 8 военно, 5
31 000 655 BLOCK, connecting .....12210 00040 4 14 44 8 144 4 4 4 a a 4 RR 4 4 a a a a 4 вен, a 1
32 010378 GROMMET, rubber 9/16 ID x 3/4 hole 1/16groove .......... cc... 1
33 605795 SCREW, self tapping-flathd 8-32 x 1/2... ii. 4
34 000741 PORTHOLE, view - gauge .......22200 00014 4e 4 eee 4 a 4 4 ee a 4 a a a 4 aa eee 1
35 000660 COVER, filler BOX ............ 2.2... aaa aaa. 1
36 NAMEPLATE (order by stock, model and style numbers} .................. 1
37 602200 WASHER, lock -steel split No. 8... ....... iii inns 3
38 1 602082 SCREW, machine - steel! round hd 8-32 x 1/2 ..... iii. 3
601 965 SCREW, cap - steel hex hd 3/8-16 x 1 (attaching tank to welding unit) ......... 4
602 243 WASHER, fiat - steel standard 3/8 {attaching tank to welding unit) ........... 4
602 224 WASHER, lock - steel split 3/8 (attaching tank to weldingunit} .............. 4
602 969 PLUG, protective No. 6 plastic oii iit ei eee ene naan 1
BE SURE TO PROVIDE STOCK, MODEL, AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-621 Page 2